ROPA Keiler 2 User manual

Operating Manual
Keiler 2
Software version: 23RK21016
Printed in Germany: 10/2023
Generation 1
Edition 6
E901396GB

Translation of the Original Operating Manual
Imprint
All rights reserved
©Copyright by
ROPA Fahrzeug- und Maschinenbau GmbH
Sittelsdorf 24
D-84097 Herrngiersdorf
Phone: + 49 – 87 85 – 96 01 0
Fax: + 49 – 87 85 – 56 6
Internet www.ropa-maschinenbau.de
Email: [email protected]
This operating manual may only be reprinted or otherwise reproduced – even in
excerpts – with the express approval of ROPA GmbH. Any type of reproduction, distri-
bution or storage on data medium in any form and of any type not authorised by ROPA
GmbH forms a violation of current domestic and international copyright law and will be
judicially prosecuted.
Publisher responsible for the content:
ROPA Fahrzeug- und Maschinenbau GmbH
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Contents
Contents
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Contents
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Contents
1 Preface......................................................................... 13
1.1 Name plate and important data...............................................................17
1.2 Serial numbers of pickups.......................................................................19
1.3 Declaration of Conformity........................................................................20
1.4 Extended documentation......................................................................... 21
1.4.1 Supplier documentation and purchased parts operating manual............ 21
2 Safety........................................................................... 23
2.1 General.................................................................................................... 25
2.2 Obligations of the entrepreneur...............................................................25
2.3 General symbols and instructions........................................................... 26
2.3.1 Safety signs............................................................................................. 27
2.4 Proper use............................................................................................... 28
2.4.1 Foreseeable misuse:............................................................................... 28
2.5 Hazard zone............................................................................................ 29
2.6 Safety stickers on the machine............................................................... 31
2.7 Safety and health protection................................................................... 35
2.8 Requirements for the operating and maintenance personnel..................36
2.9 Use of the boarding steps.......................................................................36
2.10 In the event of accidents.........................................................................36
2.11 Handling and process materials..............................................................37
2.12 Residual risks.......................................................................................... 37
2.13 Hazards caused by mechanical influences............................................. 37
2.14 Hazards caused by electromagnetic influences...................................... 37
2.15 Hazards caused by electricity................................................................. 38
2.16 Hazards caused by process materials.................................................... 39
2.17 Hazards caused by noise........................................................................39
2.18 Hazards caused by the hydraulic system............................................... 40
2.19 Hazards caused by pneumatic system................................................... 40
2.20 Hazards caused by hot substances/surfaces..........................................40
2.21 Risks due to drive shafts.........................................................................41
2.22 Stability with the side-driven harvester....................................................41
2.23 Personal protective equipment................................................................42
2.24 Leakage................................................................................................... 42
2.25 Prohibition of unauthorised modifications and alterations....................... 42
2.26 Safety and protective equipment.............................................................43
2.27 Immobiliser...............................................................................................44
3 Technical data and general view...............................45
3.1 Technical data..........................................................................................47
3.2 Tyre pressure...........................................................................................49
3.3 General overview.....................................................................................50
3.4 Transport draft for low-loader transport of the bunker machine.............. 53
3.5 Transport draft for low-loader transport of the overloading bunker
machine....................................................................................................55
3.6 Lashing eyes for transport by low-loader/ship.........................................57
4 General Description................................................... 59
4.1 Occupation...............................................................................................61
4.2 Bunker machine scope of delivery.......................................................... 63
4.3 Overloading bunker machine scope of delivery...................................... 64
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Contents
5 Control elements........................................................ 65
5.1 Ladders.................................................................................................... 67
5.1.1 Left ladder................................................................................................67
5.1.2 Right ladder............................................................................................. 69
5.1.3 DoubleSelect ladder................................................................................ 71
5.2 Overview of tractor operating components............................................. 72
5.2.1 Tractor terminal........................................................................................73
5.2.2 Lifter operating component......................................................................74
5.2.3 Bunker control element (bunker machine).............................................. 76
5.2.4 Freely assignable control element.......................................................... 79
5.2.5 Video terminal for digital video system (option)...................................... 80
5.3 Overview of machine controls................................................................. 81
5.3.1 Control unit above picking conveyor....................................................... 81
5.3.2 Control unit above central electrical system............................................82
5.3.3 Control elements above DoubleSelect platform...................................... 83
6 Operation..................................................................... 85
6.1 First startup..............................................................................................88
6.1.1 Adjustment of the drawbar eye............................................................... 89
6.1.1.1 Drawbar eye ball..................................................................................... 90
6.1.1.2 Drawbar eye hitch (export)......................................................................91
6.1.2 Adjustment of the cardan shaft............................................................... 92
6.1.3 Adjusting the hydraulic system................................................................92
6.1.4 Number plate........................................................................................... 94
6.1.5 Installing the electrics on the tractor....................................................... 95
6.2 Safety regulations during operation of the machine................................98
6.2.1 Working in the vicinity of overhead power lines...................................... 99
6.2.2 Behaviour during or after contact to the power lines.............................100
6.3 Operating concept with ISOBUS...........................................................101
6.3.1 Tractor terminal......................................................................................101
6.3.1.1 AUX-N – Auxiliary Control (new)...........................................................102
6.3.1.1.1 Generally supported AUX-N functions of the machine..........................102
6.3.1.1.2 Supported AUX-N functions of the bunker machine............................. 104
6.3.1.1.3 Supported AUX-N functions of the overloading bunker machine.......... 105
6.3.1.2 Task Controller basic (option)................................................................107
6.3.1.3 Tractor terminal display areas............................................................... 108
6.3.1.3.1 ESC key.................................................................................................110
6.3.1.3.2 Road mode............................................................................................ 111
6.3.1.3.3 Field operation menu.............................................................................112
6.3.1.3.4 Folding mode menu...............................................................................115
6.3.1.3.5 Pickup menu..........................................................................................118
6.3.1.3.6 Sieving channel menu........................................................................... 124
6.3.1.3.7 Separation menu................................................................................... 129
6.3.1.3.8 Picking table menu................................................................................ 134
6.3.1.3.9 Menu for manual control of conveyors..................................................135
6.3.1.3.10 Drive wheel menu..................................................................................137
6.3.1.4 Main menu.............................................................................................138
6.3.1.4.1 Programmable keys...............................................................................139
6.3.1.4.2 Main settings menu............................................................................... 141
6.3.1.4.3 Special functions....................................................................................147
6.3.1.4.4 Operating data.......................................................................................148
6.3.1.4.5 Video menu............................................................................................150
6.3.1.4.6 Menu AUXILIARY ISOBUS................................................................... 150
6.3.1.4.7 Service menu.........................................................................................151
6.3.1.5 Readjusting of thresholds......................................................................152
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Contents
6.3.1.5.1 Load-dependant automatic control of sieve conveyor 2 and pintle 1.....153
6.3.1.6 Warning and status indications on the tractor terminal......................... 155
6.3.2 Machine terminal................................................................................... 158
6.3.2.1 Machine terminal display areas.............................................................159
6.3.2.1.1 Sorting platform menu 1........................................................................161
6.3.2.1.2 Sorting platform menu 2........................................................................162
6.3.2.1.3 Sorting platform menu 3........................................................................163
6.3.2.1.4 Sorting platform menu 4........................................................................164
6.3.3 Freely assignable control element.........................................................165
6.3.4 Video terminal for digital video system (option).................................... 173
6.3.4.1 Video terminal display areas................................................................. 174
6.3.4.2 Configuration of camera views..............................................................175
6.3.4.3 Video terminal cleaning mode...............................................................177
6.3.4.4 Video terminal main menu.................................................................... 177
6.3.4.4.1 Video terminal system menu.................................................................178
6.3.4.4.2 Video terminal service menu.................................................................181
6.4 Support foot........................................................................................... 182
6.5 Coupling and uncoupling the machine..................................................183
6.5.1 Coupling machine.................................................................................. 183
6.5.2 Uncoupling the machine........................................................................186
6.6 Road travel............................................................................................ 187
6.6.1 General.................................................................................................. 187
6.7 Braking system...................................................................................... 189
6.7.1 Pneumatic service brake....................................................................... 189
6.7.2 Hydraulic service brake......................................................................... 191
6.7.3 Emergency brake...................................................................................192
6.8 Steering..................................................................................................193
6.8.1 Steering in the Road operating mode................................................... 193
6.8.2 Steering in the Field operating mode.................................................... 193
6.8.2.1 Drawbar steering................................................................................... 194
6.8.2.1.1 Drawbar guard (option)......................................................................... 195
6.8.2.1.2 Drawbar tool tray (option)......................................................................196
6.8.2.2 Axle steering..........................................................................................196
6.9 Chassis.................................................................................................. 199
6.9.1 Slope compensation display field on the tractor terminal...................... 199
6.9.2 Hydraulic slope compensation including automatic function................. 199
6.9.3 Telescopic axle...................................................................................... 201
6.9.4 Drive wheel (option).............................................................................. 202
6.9.5 Additional axle (option)..........................................................................205
6.10 Sunroof/weather protection roof (optional)............................................ 207
6.10.1 Canopy lighting (option)........................................................................ 208
6.11 Lifting......................................................................................................209
6.11.1 Preparation for lifting............................................................................. 209
6.11.2 Lifting process........................................................................................210
6.12 Pickup.................................................................................................... 211
6.12.1 Ridge pickup..........................................................................................212
6.12.1.1 Ridge roller............................................................................................ 212
6.12.1.2 Ridge centring........................................................................................213
6.12.1.3 Shares....................................................................................................215
6.12.1.4 Lifting depth and ridge pressure regulation...........................................217
6.12.1.4.1 Lifting depth........................................................................................... 217
6.12.1.4.2 Ridge pressure regulation..................................................................... 222
6.12.1.5 Disc coulter............................................................................................227
6.12.1.6 Single row pickup.................................................................................. 231
6.12.1.7 Leaf loading roller..................................................................................234
6.12.1.8 Setting row distance.............................................................................. 234
6.12.2 Pickup model without ridge rollers........................................................ 236
6.12.2.1 Lifting depth and ridge pressure relief...................................................237
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Contents
6.12.2.1.1 Lifting depth pickup w/o ridge rollers.....................................................237
6.12.2.1.2 Ridge pressure relief of the pickup without ridge rollers....................... 238
6.12.2.2 Disc coulter............................................................................................238
6.12.2.3 Setting row distance.............................................................................. 239
6.12.3 Swath pickup model with lifting shaft and cover belt.............................240
6.12.4 Swath pickup model with shares...........................................................243
6.12.5 Pickup model for carrots....................................................................... 244
6.12.6 Ridge pressure relief............................................................................. 245
6.13 Cleaning.................................................................................................250
6.13.1 Sieving channel and leaf separation..................................................... 250
6.13.1.1 Lifter chain (option)................................................................................251
6.13.1.2 Sieve conveyor 1...................................................................................252
6.13.1.3 Stainless steel plates in sieving channel (option)..................................256
6.13.1.4 Clod breaker of sieve conveyor 1 (option)............................................ 256
6.13.1.5 Sieve conveyor 1 cleaning roller (option)..............................................257
6.13.1.6 Rubber paddle roller sieve conveyor 1 (option).................................... 258
6.13.1.7 Shaker....................................................................................................258
6.13.1.8 Sieve conveyor 2...................................................................................261
6.13.1.9 Clod breaker of sieve conveyor 2 (option)............................................ 265
6.13.1.10 Transition lock sieve conveyor 2 (option)..............................................265
6.13.1.11 Synchronous adjustment of sieve conveyors........................................ 266
6.13.1.12 Drive speed-dependent sieve conveyor automatic control....................269
6.13.1.13 Leaf chain.............................................................................................. 274
6.13.1.14 Leaf scrapers.........................................................................................280
6.13.1.15 Pull-off rods in the leaf separation........................................................ 284
6.13.2 Separation..............................................................................................285
6.13.2.1 Pintle belt 1............................................................................................ 285
6.13.2.2 Drive speed-dependent pintle belt automatic control............................ 289
6.13.2.3 Deflector roller 1.................................................................................... 292
6.13.2.4 Dirt discharge conveyor.........................................................................295
6.13.2.5 Pintle belt 2............................................................................................296
6.13.2.6 Deflector roller 2.................................................................................... 300
6.13.2.7 DoubleSelect (option)............................................................................ 304
6.13.2.8 Pintle belt 1/2 inclination........................................................................305
6.13.2.9 Pintle belt 3............................................................................................309
6.13.2.10 Deflector roller 3.................................................................................... 313
6.13.2.11 Pintle belt 4............................................................................................316
6.13.2.12 Rotating finger comb (UFK).................................................................. 320
6.13.2.13 Pintle belt 4 inclination........................................................................... 325
6.13.2.14 Synchronous adjustment of pintle belts................................................ 328
6.13.3 Picking....................................................................................................333
6.13.3.1 Picking conveyor....................................................................................334
6.13.3.2 Trash conveyor...................................................................................... 338
6.13.3.3 Trash conveyor reverse (option)........................................................... 342
6.13.3.4 Trash discharge conveyor..................................................................... 344
6.13.3.5 Collection box (option)...........................................................................344
6.13.3.6 Potato crusher (option)..........................................................................345
6.14 Bunker....................................................................................................347
6.14.1 Bunker folding section and bunker flap.................................................348
6.14.2 Raising/lowering bunker........................................................................ 350
6.14.3 Bunker walking floor.............................................................................. 351
6.14.4 Bunker filling conveyor.......................................................................... 352
6.14.5 Filling bunker at bunker machine.......................................................... 353
6.15 Unloading bunker at bunker machine................................................... 357
6.15.1 Articulated bunker section (optional)..................................................... 358
6.15.2 Tray filler (optional)................................................................................359
6.15.3 Reset bunker floor................................................................................. 360
6.16 Bunker scales (option)...........................................................................361
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Contents
6.16.1 Design and function...............................................................................361
6.16.2 Weighing................................................................................................ 362
6.16.2.1 Operation of scales............................................................................... 363
6.16.2.2 Commissioning after delivery of machine............................................. 364
6.16.2.3 Start/end weighing................................................................................. 364
6.16.2.4 Set current weighed amount to 0..........................................................365
6.16.2.5 Run zeroing........................................................................................... 365
6.16.2.6 Calibrate scales..................................................................................... 366
6.16.2.7 Continuing operation of scales..............................................................367
6.16.2.8 Counter.................................................................................................. 368
6.17 Overloading bunker (option)..................................................................369
6.17.1 Unload conveyor and bunker rear wall................................................. 370
6.17.2 Walking floor bunker trough and unloading conveyor........................... 374
6.17.3 Bunker filling conveyor and picking conveyor....................................... 375
6.17.4 Filling bunker at overloading bunker machine.......................................376
6.18 Bunker unloading with overloading bunker........................................... 380
6.18.1 Tray filler overloading bunker (option)...................................................382
6.19 Pump distributor gears.......................................................................... 383
6.20 Hydraulic system................................................................................... 385
6.21 Compressed air system.........................................................................388
6.21.1 Compressed air reservoir...................................................................... 388
6.22 Central lubricating system (optional)..................................................... 389
6.22.1 Intermediate lubrication......................................................................... 391
6.23 Video system (option)............................................................................392
6.23.1 Analogue video system (option)............................................................393
6.23.1.1 ROPA video switch (option).................................................................. 397
6.23.2 Digital video system (option)................................................................. 400
6.24 Electrics..................................................................................................402
6.24.1 Voltage monitoring.................................................................................402
6.24.2 Fuses..................................................................................................... 402
6.25 Shutdown............................................................................................... 403
7 Maintenance and service.........................................405
7.1 Pump distributor gears (PDG)...............................................................408
7.2 Hydraulic system................................................................................... 409
7.2.1 Hydraulic fluid tank for machine hydraulics...........................................411
7.2.1.1 Changing hydraulic fluid........................................................................ 412
7.2.1.2 Replacing return filter element.............................................................. 414
7.2.2 Replacing tractor hydraulic system pressure filter element...................416
7.2.3 Exchanging the drive wheel suction filter element................................ 417
7.3 Axle........................................................................................................ 418
7.4 Pneumatic system................................................................................. 419
7.5 Pickup.................................................................................................... 420
7.5.1 Ridge pickup..........................................................................................420
7.5.1.1 Ridge roller............................................................................................ 420
7.5.1.1.1 Ridge roller wiper.................................................................................. 420
7.5.1.1.2 Adjusting ridge centring sensor.............................................................421
7.5.2 Pickup model without ridge rollers........................................................ 422
7.5.3 Swath pickup model.............................................................................. 423
7.5.3.1 Adjustment of cover belt tension and synchronous run........................ 423
7.5.3.2 Swath pickup gears............................................................................... 424
7.5.4 Shares....................................................................................................425
7.5.5 Disc coulter............................................................................................425
7.5.6 Hydraulic disc coulter (optional)............................................................ 426
7.5.7 Leaf loading roller..................................................................................427
7.6 Sieving channel and leaf separation..................................................... 428
7.6.1 Lifter chain............................................................................................. 428
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Contents
7.6.1.1 Tension...................................................................................................428
7.6.1.2 Replacing lifter chain............................................................................. 429
7.6.2 Sieve conveyor 1...................................................................................429
7.6.2.1 Tension...................................................................................................430
7.6.2.2 Adjustment of synchronous run.............................................................431
7.6.2.3 Replacing sieve conveyor 1.................................................................. 432
7.6.3 Shaker....................................................................................................432
7.6.4 Sieve conveyor 2...................................................................................433
7.6.4.1 Tension...................................................................................................433
7.6.4.2 Adjustment of synchronous run.............................................................434
7.6.4.3 Replacing sieve conveyor 2.................................................................. 435
7.6.5 Leaf chain.............................................................................................. 435
7.6.5.1 Tension...................................................................................................436
7.6.5.2 Adjustment of synchronous run.............................................................437
7.6.5.3 Replacing leaf chain.............................................................................. 438
7.6.6 Leaf scrapers.........................................................................................439
7.7 Separation..............................................................................................440
7.7.1 Pintle belt 1............................................................................................440
7.7.1.1 Tension...................................................................................................440
7.7.1.2 Adjustment of synchronous run.............................................................441
7.7.2 Deflector roller 1.................................................................................... 443
7.7.3 Dirt discharge conveyor.........................................................................444
7.7.3.1 Adjustment of tension and synchronous run.........................................444
7.7.4 Pintle belt 2............................................................................................445
7.7.4.1 Tension...................................................................................................445
7.7.4.2 Adjustment of synchronous run.............................................................446
7.7.5 Deflector roller 2.................................................................................... 447
7.7.6 Pintle belt 1/2 inclination....................................................................... 447
7.7.7 Pintle belt 3............................................................................................448
7.7.7.1 Adjustment of tension and synchronous run.........................................448
7.7.8 Deflector roller 3.................................................................................... 449
7.7.9 Pintle belt 4............................................................................................450
7.7.9.1 Adjustment of tension and synchronous run.........................................450
7.7.10 Rotating finger comb (UFK).................................................................. 451
7.7.10.1 Adjustment of tension and synchronous run.........................................451
7.7.11 Pintle belt 4 inclination.......................................................................... 452
7.8 Picking conveyor....................................................................................453
7.8.1 Adjustment of tension and synchronous run.........................................453
7.9 Trash conveyor...................................................................................... 454
7.9.1 Adjustment of tension and synchronous run.........................................454
7.10 Trash discharge conveyor..................................................................... 455
7.10.1 Adjustment of tension and synchronous run.........................................455
7.11 Collection box........................................................................................ 456
7.11.1 Adjustment of tension and synchronous run.........................................456
7.12 Potato crusher....................................................................................... 457
7.12.1 Distance adjustment.............................................................................. 457
7.12.2 Tension adjustment................................................................................458
7.13 Locks......................................................................................................459
7.14 Bunker....................................................................................................460
7.14.1 Ultrasound sensor..................................................................................460
7.14.2 Bunker walking floor.............................................................................. 461
7.14.2.1 Tension of bunker walking floor chains................................................. 462
7.14.2.2 Drive chains...........................................................................................463
7.15 Overloading bunker............................................................................... 464
7.15.1 Ultrasound sensors................................................................................464
7.15.2 Walking floor.......................................................................................... 465
7.15.2.1 Walking floor tensioning........................................................................ 466
7.15.2.2 Walking floor drive chain....................................................................... 467
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